Mandrel

Abstract

Pixel wells and a grid of electrical lines including electrical bridges are formed using an ultraviolet transparent mandrel having a three-dimensional surface and an integrated mask.

1. A method comprising:
 forming pixel wells and a grid of electrical lines including electrical bridges using an ultraviolet transparent mandrel having a three-dimensional surface and an integral mask layer, wherein proud portions of the three-dimensional surface defines a first set of electrical lines and wherein the integral mask layer defines a second set of electrical lines. 
 
     
     
       2. The method of  claim 1 , wherein the grid of electrical lines is formed by using both positive and negative photopolymers with the integral mask layer to form a channel having a floor of a first polarity photopolymer and side walls of a second opposite polarity photopolymer that define edges of the electrical lines. 
     
     
       3. The method of  claim 1 , wherein forming pixel wells in the grid comprises:
 patterning a catalytic material upon the mandrel using the integral mask layer; 
 patterning a negative photopolymer using the integral mask layer to form a channel adjacent the patterned catalytic material; and 
 electrolessly plating an electrically conductive material upon the patterned catalytic material to form a first set of the electrical lines. 
 
     
     
       4. The method of  claim 3 , wherein the step of patterning the catalytic material includes:
 coating the catalytic material over the mandrel; and 
 photo imaging the catalytic material on a first side of the mandrel by transmitting ultraviolet light through the mandrel from a second opposite side of the mandrel. 
 
     
     
       5. The method of  claim 4 , wherein the step of patterning the negative photopolymer includes:
 coating the negative photopolymer upon the patterned catalytic material; and 
 photo imaging the negative photopolymer on a first side of the mandrel by transmitting ultraviolet light through the mandrel from a second opposite side of the mandrel. 
 
     
     
       6. The method of  claim 3 , wherein the step of patterning the negative photopolymer includes:
 coating the negative photopolymer upon the patterned catalytic material and 
 photo imaging the negative photopolymer on a first side of the mandrel by transmitting ultraviolet light through the mandrel from a second opposite side of the mandrel. 
 
     
     
       7. The method of  claim 1 , wherein the proud portions include a transparent conductor thereon and wherein the electrically conductive material is electroplated upon the transparent conductor to form the first set of electrical lines. 
     
     
       8. The method of  claim 1 , wherein the electroplating is configured such that the electrically conductive material bridges over an electrical line of the second set of electrical lines during electroplating to form a electrical bridge. 
     
     
       9. The method of  claim 1 , wherein the mandrel has a first level used to locate a first set of electrical lines, a second-level used to locate a second set of electrical lines orthogonal to the first set of electrical lines and a third level used to locate a floor of the pixel wells. 
     
     
       10. The method of  claim 9 , wherein the second level is between the first level and the third level. 
     
     
       11. The method of  claim 1 , wherein the mandrel is separated from the formed pixel wells and grid of electrical lines to expose a surface previously adjacent the mandrel. 
     
     
       12. The method of  claim 11 , further comprises bonding the surface to another structure including a second set of formed pixel wells and a second grid of electrical lines to form a stack of display grids. 
     
     
       13. The method of  claim 1 , wherein the ultraviolet transparent mandrel comprises:
 first portions configured to transmit ultraviolet light; 
 second portions configured to attenuate ultraviolet light; and 
 a surface having a varying topography. 
 
     
     
       14. The method of  claim 13 , wherein one of the first portions and the second portions is arranged in a grid. 
     
     
       15. The method of  claim 14 , wherein the varying topography of the surface comprises:
 a first set of channels; and 
 a second set of channels non-parallel to the first set of channels. 
 
     
     
       16. The method of  claim 15 , wherein the varying topography of the surface further comprises a set of spaced projecting walls. 
     
     
       17. The method of  claim 16 , wherein the mandrel further comprises a transparent electrically conductive material on a top of the projecting walls. 
     
     
       18. The method of  claim 1 , wherein the pixel wells are arranged in a grid integrally part of a single unitary body, each of the pixel wells including side walls and a floor and wherein the grid of electrical lines including electrical bridges comprises:
 a first conductor line recessed below the floor; 
 a catalytic material line extending non-parallel to the first conductor line; 
 a second conductor line on the catalytic material line; 
 a dielectric layer on the second conductor line, wherein the first conductor line is electroplated across the dielectric layer on the second conductor line. 
 
     
     
       19. The method of  claim 18 , wherein the pixel wells comprise a photopolymer forming channel walls in alignment with edges of the catalytic material line and contacting opposite side edges of the second conductor line. 
     
     
       20. A method comprising:
 forming pixel wells and a grid of electrical lines including electrical bridges using an ultraviolet transparent mandrel having a three-dimensional surface and an integral mask layer, wherein the grid of electrical lines is formed by using both positive and negative photopolymers with the integral mask layer to form a channel having a floor of a first polarity photopolymer and side walls of a second opposite polarity photopolymer that define edges of the electrical lines. 
 
     
     
       21. A method comprising:
 forming pixel wells and a grid of electrical lines including electrical bridges using an ultraviolet transparent mandrel having a three-dimensional surface and an integral mask layer, wherein forming pixel wells in the grid comprises: 
 patterning a catalytic material upon the mandrel using the integral mask layer; 
 patterning a negative photopolymer using the integral mask layer to form a channel adjacent the patterned catalytic material; and 
 electrolessly plating an electrically conductive material upon the patterned catalytic material to form a first set of the electrical lines. 
 
     
     
       22. The method of  claim 21 , wherein the step of patterning the catalytic material includes:
 coating the catalytic material over the mandrel; and 
 photo imaging the catalytic material on a first side of the mandrel by transmitting ultraviolet light through the mandrel from a second opposite side of the mandrel. 
 
     
     
       23. The method of  claim 22 , wherein the step of patterning the negative photopolymer includes:
 coating the negative photopolymer upon the patterned catalytic material; and 
 photo imaging the negative photopolymer on a first side of the mandrel by transmitting ultraviolet light through the mandrel from a second opposite side of the mandrel. 
 
     
     
       24. The method of  claim 21 , wherein the step of patterning the negative photopolymer includes:
 coating the negative photopolymer upon the patterned catalytic material and 
 photo imaging the negative photopolymer on a first side of the mandrel by transmitting ultraviolet light through the mandrel from a second opposite side of the mandrel. 
 
     
     
       25. A method comprising:
 forming pixel wells and a grid of electrical lines including electrical bridges using an ultraviolet transparent mandrel having a three-dimensional surface and an integral mask layer, wherein the mandrel has a first level used to locate a first set of electrical lines, a second-level used to locate a second set of electrical lines orthogonal to the first set of electrical lines and a third level used to locate a floor of the pixel wells. 
 
     
     
       26. The method of  claim 25 , wherein the second level is between the first level and the third level. 
     
     
       27. A method comprising:
 forming pixel wells and a grid of electrical lines including electrical bridges using an ultraviolet transparent mandrel having a three-dimensional surface and an integral mask layer, wherein the ultraviolet transparent mandrel comprises: 
 first portions configured to transmit ultraviolet light; 
 second portions configured to attenuate ultraviolet light, wherein one of the first portions and the second portions is arranged in a grid; and 
 a surface having a varying topography, wherein the varying topography of the surface comprises: 
 a first set of channels; and 
 a second set of channels non-parallel to the first set of channels. 
 
     
     
       28. The method of  claim 27 , wherein the varying topography of the surface further comprises a set of spaced projecting walls. 
     
     
       29. The method of  claim 28 , wherein the mandrel further comprises a transparent electrically conductive material on a top of the projecting walls. 
     
     
       30. A method comprising:
 forming pixel wells and a grid of electrical lines including electrical bridges using an ultraviolet transparent mandrel having a three-dimensional surface and an integral mask layer, wherein the pixel wells are arranged in a grid integrally part of a single unitary body, each of the pixel wells including side walls and a floor and wherein the grid of electrical lines including electrical bridges comprises: 
 a first conductor line recessed below the floor; 
 a catalytic material line extending non-parallel to the first conductor line; 
 a second conductor line on the catalytic material line; 
 a dielectric layer on the second conductor line, wherein the first conductor line is electroplated across the dielectric layer on the second conductor line. 
 
     
     
       31. The method of  claim 30 , wherein the pixel wells comprise a photopolymer forming channel walls in alignment with edges of the catalytic material line and contacting opposite side edges of the second conductor line.